General Mechanics 01
Customer request
The high material removal index (93%), combined with the material’s characteristics (Aluminium), cause significant deformation of the part. Which approach could optimize the manufacturing process in order to minimize: the total set-up time, the total cycle time and the number of stages?
Here below the FCS solution.
What the customer asked
Reduce the total cycle time
Reduce the total set-up time
Reduce the manufacturing stages (OP)
Managing deformation (Avoid Shimming)
Short pay-back period
Our solution
High efficiency process in four machining stages (lugs removal fully performed by milling).
Whitstanding to keep well hold the workpiece without forcing its geometry, clamping adaptability for handling the stress relieving coming from the metal cutting deformation and control of the alignment. Quick and manual locking-unlocking.
In addition, the clamping components can be used for other applications (reconfigurable equipment).
Manufacturing Process Overview
OP 10
Machining:
Roughing till to +1mm from the finished geometry.
Clamping equipment:
Bottom reference plate D500 mm and Self centering vise (gripping height 5mm).
OP 20
Machining:
Roughing on the top side, leaving enough extra material (according to the expected deformation). Stress relieving. Finishing.
Clamping equipment:
Bottom reference plate D500 mm and Body adjustable M12 H120 + Body reduction M12-M6 H30.
OP 30
Machining: Finishing
Clamping equipment: Bottom reference plate D500 mm and fixed Body M12 H120 + Body reduction M12-M6 H30.
LUGS REMOVAL
Machining: Lugs removal
Clamping equipment: Bottom reference plate D500 mm and fixed Body M12 H120 + Body reduction M12-M6 H30.
The extra material left to make the connection with the supports will be fully cutted-out by milling as last operation at this stage.
The gripping pliers will hold the part once the plugs are removed, otherwise the part would fall.
Additional Resources
Technical Project Data
- Sector: General Mechanics
- Material Type: Aluminum 7075
- Raw Block overall size: 240x200x50 mm
- Finished Part overall size: 213x187x39 mm
- Raw block weight: 6,64kg
- Finished part weight: 0,46 kg
- Material removal index (MRI): 93%
- Accuracy: 0,10 mm
Classification Tags
- Material Category: Light Alloy
- Accuracy: Medium
- Material removal index (MRI): High
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